U.S. patent application number 13/274148 was filed with the patent office on 2013-04-18 for shingle coloring system.
The applicant listed for this patent is Daniel E. Boss, Michael L. Bryson, Stephen A. Buzza, Adem Chich, Dale A. Kelley, Matti Kiik, Paul Richardson, Tommy Rodrigues, James A. Svec, James D. Wells. Invention is credited to Daniel E. Boss, Michael L. Bryson, Stephen A. Buzza, Adem Chich, Dale A. Kelley, Matti Kiik, Paul Richardson, Tommy Rodrigues, James A. Svec, James D. Wells.
Application Number | 20130095293 13/274148 |
Document ID | / |
Family ID | 48086174 |
Filed Date | 2013-04-18 |
United States Patent
Application |
20130095293 |
Kind Code |
A1 |
Boss; Daniel E. ; et
al. |
April 18, 2013 |
Shingle Coloring System
Abstract
Disclosed painted roof coverings and related methods of
manufacturing such painted roof coverings that use a color coating
over the roof coverings instead of embedded pre-colored rock
granules on the exposed surface of the roof coverings. By painting
a roof covering with a color coating, any kind of top surfacing
material, such as rock, plastic, mineral, man-made, or organic
granules, may be used in place of the pre-colored rock granules. In
some embodiments, it is desirable to size the top surfacing
material to provide adequate UV protection and coverage to the
weatherproofing asphalt material located below the top surfacing
material. Further, the color of the shingles may be accurately
matched between batches of shingles, between manufacturing
facilities, and even between manufacturers. In addition, designs
may be painted on the surface of the roof covering, which was
previously impossible using pre-colored granules.
Inventors: |
Boss; Daniel E.; (Murphy,
TX) ; Bryson; Michael L.; (Independence, MO) ;
Buzza; Stephen A.; (New Burgh, IN) ; Chich; Adem;
(Kearny, NJ) ; Kelley; Dale A.; (Flower Mound,
TX) ; Kiik; Matti; (Richardson, TX) ;
Richardson; Paul; (Euless, TX) ; Rodrigues;
Tommy; (Nutley, NJ) ; Svec; James A.;
(Kilarny, NJ) ; Wells; James D.; (Bakersfield,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Boss; Daniel E.
Bryson; Michael L.
Buzza; Stephen A.
Chich; Adem
Kelley; Dale A.
Kiik; Matti
Richardson; Paul
Rodrigues; Tommy
Svec; James A.
Wells; James D. |
Murphy
Independence
New Burgh
Kearny
Flower Mound
Richardson
Euless
Nutley
Kilarny
Bakersfield |
TX
MO
IN
NJ
TX
TX
TX
NJ
NJ
CA |
US
US
US
US
US
US
US
US
US
US |
|
|
Family ID: |
48086174 |
Appl. No.: |
13/274148 |
Filed: |
October 14, 2011 |
Current U.S.
Class: |
428/147 ;
156/276; 156/280; 428/143; 428/148; 442/64; 442/65; 442/71;
53/428 |
Current CPC
Class: |
B32B 38/14 20130101;
Y10T 428/24405 20150115; E04D 1/20 20130101; Y10T 442/2098
20150401; B32B 2395/00 20130101; Y10T 442/2041 20150401; B32B 38/08
20130101; Y10T 442/2049 20150401; Y10T 428/24372 20150115; B32B
37/24 20130101; Y10T 428/24413 20150115; E04D 5/12 20130101; B32B
2419/06 20130101; E04D 2001/005 20130101; B32B 11/10 20130101; B32B
2315/085 20130101 |
Class at
Publication: |
428/147 ;
156/280; 156/276; 428/143; 428/148; 53/428; 442/64; 442/71;
442/65 |
International
Class: |
E04D 1/28 20060101
E04D001/28; B32B 11/10 20060101 B32B011/10; D06N 7/04 20060101
D06N007/04; B65B 55/00 20060101 B65B055/00; B32B 38/08 20060101
B32B038/08; B32B 11/02 20060101 B32B011/02 |
Claims
1. A colored roofing covering comprising: a fiberglass mat
comprising an upper surface and a lower surface; a first asphalt
filled coating layer disposed on the upper surface of the
fiberglass mat, wherein the first asphalt filled coating layer is
operable to provide a substantially waterproof barrier for the
upper surface of the fiberglass mat; a layer of top surfacing
material disposed on the first asphalt filled coating layer; and a
color coating layer disposed on the layer of top surfacing
material.
2. The colored roofing covering of claim 1, wherein the layer of
top surfacing material comprises a plurality of individual
granules.
3. The colored roofing covering of claim 2, wherein the individual
granules are selected from the group consisting of rock, clay,
polymer plastic, manufactured mineral, organic compound, or metal
flake.
4. The colored roofing covering of claim 3, wherein the individual
granules are Grade 18 sized granules.
5. The colored roofing covering of claim 1, wherein the color
coating layer comprises a layer of paint.
6. The colored roofing covering of claim 5, wherein the paint
selected from the group consisting of acrylic-based paints,
oil-based paints, polyurethane-based paints, polyurethane
acrylate-based paints, polyvinylidene fluoride-based paints, or any
combination thereof.
7. The colored roofing covering of claim 5, wherein the color
coating layer is applied approximately 5 microns thick.
8. The colored roofing covering of claim 1, wherein the color
coating layer comprises a layer of ink.
9. The colored roofing covering of claim 8, wherein the ink
comprises at least two of the following: oligomers, monomers, a
photo initiator, colorants, modifiers, and additives.
10. The colored roofing covering of claim 1 further comprising a
pre-coat layer disposed between the layer of top surfacing material
and the color coating layer.
11. The colored roofing covering of claim 1 further comprising a
clear-coat layer disposed on top of the color coating layer.
12. The colored roofing covering of claim 1, further comprising a
second asphalt filled coating layer disposed on the lower surface
of the fiberglass mat, wherein the second asphalt filled coating
layer is operable to provide a substantially waterproof barrier for
the lower surface of the fiberglass mat.
13. The colored roofing covering of claim 1, further comprising a
layer of back surfacing material disposed on the second asphalt
filled coating layer.
14. A method for manufacturing a colored roofing covering
comprising: providing a fiberglass mat comprising an upper surface
and a lower surface; disposing a first asphalt filled coating layer
on the upper surface of the fiberglass mat, wherein the first
asphalt filled coating layer is operable to provide a substantially
waterproof barrier for the upper surface of the fiberglass mat;
disposing a layer of top surfacing material on the first asphalt
filled coating layer; and disposing a color coating layer on the
layer of top surfacing material;
15. The method for manufacturing the colored roofing covering of
claim 14, wherein the layer of top surfacing material comprises a
plurality of individual granules.
16. The method for manufacturing the colored roofing covering of
claim 14, wherein disposing a color coating layer comprises
spraying a layer of paint and controlling the spraying with a
computer.
17. The method for manufacturing the colored roofing covering of
claim 14, wherein disposing a color coating layer comprises inject
a layer of ink and controlling the injecting with a computer.
18. The method for manufacturing the colored roofing covering of
claim 14, further comprising disposing a pre-coat layer between the
layer of top surfacing material and the color coating layer.
19. The method for manufacturing the colored roofing covering of
claim 14, further comprising disposing a clear-coat layer on top of
the color coating layer.
20. The method for manufacturing the colored roofing covering of
claim 14, further comprising disposing a second asphalt filled
coating layer on the lower surface of the fiberglass mat, wherein
the second asphalt filled coating layer is operable to provide a
substantially waterproof barrier for the lower surface of the
fiberglass mat.
21. The method for manufacturing the colored roofing covering of
claim 14, further comprising disposing a layer of back surfacing
material on the second asphalt filled coating layer.
22. The method for manufacturing the colored roofing covering of
claim 14, further comprising packaging the manufactured colored
roofing covering.
23. The method for manufacturing the colored roofing covering of
claim 14, further comprising palletizing the packaged colored
roofing covering.
24. A method for preparing packaged colored roofing coverings
comprising: manufacturing a plurality of colored roofing coverings,
the manufacturing comprising: providing a fiberglass mat comprising
an upper surface and a lower surface; disposing a first asphalt
filled coating layer on the upper surface of the fiberglass mat,
wherein the first asphalt filled coating layer is operable to
provide a substantially waterproof barrier for the upper surface of
the fiberglass mat; disposing a layer of top surfacing material on
the first asphalt filled coating layer; and disposing a color
coating layer on the layer of top surfacing material; packaging the
plurality of manufactured colored roofing coverings; and
palletizing the packaged colored roofing coverings.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to colored roofing
shingles, and more particularly, to a method to color roofing
coverings.
BACKGROUND
[0002] In the manufacture of asphalt shingles, roll roofing, and
some low-slope roofing membranes, color may be applied to the
roofing surface by using either pre-made colored granules or
naturally colored rock. The granule coverage of the shingles has
two primary purposes. First, the pre-colored granules protect the
water-shedding component of the shingle, which is most commonly a
layer of asphalt, from outdoor weathering elements such as
sunlight, rain, snow, and hail. Second, the pre-colored granules
give the shingles a pleasing appearance as the roof constitutes a
major portion of a house's aesthetic appearance.
[0003] Rock has been the most common material of choice in the
United States to cover the asphalt layer in order to protect the
asphalt layer from the sun's UV radiation. Without UV protection,
the life of an asphalt-coated shingle would be short, maybe as low
as 3 to 5 years. The addition of rock granules may increase the
expected lifetime of asphalt-based shingles to 30 years or
more.
[0004] The pre-colored granule rocks used are manufactured by two
main suppliers-3M Corporation and ISP Minerals. Both of these
manufacturers use a specific rock that has a very low translucency
and use ceramic-type coatings to color the rocks used in asphalt
shingles. The majority of the pre-colored granules are standard in
size, typically referred to as Grade 11, although a smaller size
rock is available, typically referred to as Grade 18.
[0005] The pre-colored ceramic coated granules may be supplied to a
roofing manufacturer in bulk, either by railroad car or semi
truck-load. The roofing manufactures then store each color of the
pre-colored granules in a separate storage silo. When the roofing
manufacturer wants to manufacture a run of shingles of a certain
color, one or more colors of the pre-colored granules are pulled
from storage silos in specific ratios or percentages and then are
mixed in a blender or on a blend belt to create the desired final
color. There may be two or more color blends used on any one
shingle to make a shingle that appears pleasing to the eye. For
example, the asphalt shingle color Weatheredwood may have five or
more different pre-colored ceramic coated granules that are mixed
in a specific ratio to create the appearance of the single color
Weatheredwood from afar.
[0006] One approach used to apply the pre-colored granules to the
heated asphalt shingle fabric is with a blender. The blender drops
the pre-colored granules onto a asphalt-covered fiberglass mat web
in distinct sections as it travels under the blender. Different
sections of the web may receive the various colors of the
pre-colored granules in different ratios and mixtures in order to
make the finished shingle have a better aesthetic value.
[0007] One of the limitations of blending pre-colored granules,
however, is that it is difficult to create consistency in final
colors between manufacturing facilities or even between runs of
shingles manufactured in the same facility. The cause of this
limitation is that it is difficult for the pre-colored granules to
be blended in exactly the same ratios between runs or between
manufacturing facilities, and the pre-colored granules may come
from different locations and may be slightly different in color to
begin with. In addition, the pre-colored granules may appear
slightly different based on the locations of the two manufacturing
facilities and the rock supplier. The size and shape of each
pre-colored granule may also be slightly different, which may
change the final color of the shingle.
[0008] Because of the inherent limitations of mixing pre-colored
granules to create a final color for asphalt shingles, roofers do
not like to mix the same colored shingles that come from two
different manufacturing facilities, even if the same manufacturer
operates both facilities. Also, as a result of these limitations,
roofing shingles manufacturers have been limited in the colors and
patterns that they can apply to the asphalt surface due to the
limited number of colors of pre-colored granules provided to them
from the rock supplier. Even though limited in colors and color
patterns by the pre-colored granules, changes in the production
process may result in waste shingles and may require the production
line to be shut down and/or equipment to be changed to produce a
run of the next color of shingle.
SUMMARY
[0009] In an embodiment, a colored roofing covering comprising a
fiberglass mat comprising an upper surface and a lower surface; a
first asphalt filled coating layer disposed on the upper surface of
the fiberglass mat, wherein the first asphalt filled coating layer
is operable to provide a substantially waterproof barrier for the
upper surface of the fiberglass mat; a layer of top surfacing
material disposed on the first asphalt filled coating layer; and a
color coating layer disposed on the layer of top surfacing material
may be disclosed.
[0010] In a further embodiment, a method for manufacturing a
colored roofing covering comprising: providing a fiberglass mat
comprising an upper surface and a lower surface; disposing a first
asphalt filled coating layer on the upper surface of the fiberglass
mat, wherein the first asphalt filled coating layer is operable to
provide a substantially waterproof barrier for the upper surface of
the fiberglass mat; disposing a layer of top surfacing material on
the first asphalt filled coating layer; and disposing a color
coating layer on the layer of top surfacing material may be
disclosed.
[0011] In a further embodiment, A method for preparing packaged
colored roofing coverings comprising: manufacturing a plurality of
colored roofing coverings, the manufacturing comprising: providing
a fiberglass mat comprising an upper surface and a lower surface;
disposing a first asphalt filled coating layer on the upper surface
of the fiberglass mat, wherein the first asphalt filled coating
layer is operable to provide a substantially waterproof barrier for
the upper surface of the fiberglass mat; disposing a layer of top
surfacing material on the first asphalt filled coating layer; and
disposing a color coating layer on the layer of top surfacing
material; packaging the plurality of manufactured colored roofing
coverings; and palletizing the packaged colored roofing coverings,
may be disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a perspective drawing of a prior art roof;
[0013] FIG. 1B is a cross-sectional drawing of a prior art
embodiment of an asphalt shingle;
[0014] FIG. 2 is a cross-sectional drawing of a painted roof
covering, in accordance with the present disclosure; and
[0015] FIG. 3 is a flow diagram of a process for manufacturing the
colored roofing covering of FIG. 2, in accordance with the present
disclosure.
DETAILED DESCRIPTION
[0016] Disclosed herein are painted roof coverings and related
methods of manufacturing using paint and/or ink to replace
pre-colored rock granules on the exposed surface of roof coverings.
Any kind of rock, plastic, man-made, mineral, or organic substance
sized to any functional dimension that provides adequate UV
protection or coverage to a layer of waterproofing asphalt may be
used and may be painted with a layer of paint or ink in any color,
pattern, or design.
[0017] FIG. 1A is a prior art roof 100. The roof 100 may comprise a
roof support 102 and roof coverings 104 covering the roof support
102. The roof 100 may be a pitched roof covered by asphalt shingles
as the roof coverings 104. The roof support 102 may be comprised of
beams and/or trusses (not shown) made from pressure treated wood,
cast iron, or steel. The trusses may be covered with sheets of
plywood, providing a continuous surface on the roof support 102 to
which the roof coverings 104 may be affixed. Because the roof
support 102 may be manufactured from wood, the roof support 102 may
be susceptible to the elements, including rain, snow, hail, heat,
and cold. Accordingly, the roof support 102 may be protected from
the elements by the roof coverings 104 and a layer of underlayment
(not shown) disposed therebetween. According to local building
code, the layer of underlayment (not shown) may be required by law
and may be applied directly to a plywood roof support 102 below the
roof coverings 104. The roof coverings 104 used to protect the roof
support 102 from the elements may be asphalt shingles covered with
pre-colored rock granules, as described in more detail below.
[0018] FIG. 1B is a cross-sectional drawing of a prior art asphalt
shingles 104 of FIG. 1A. The asphalt shingles 104 may comprise
various layers, including a fiberglass mat 106 and an asphalt
filled coating 108 disposed thereon. The asphalt filled coating 108
may provide a waterproof barrier for the asphalt singles 104,
protecting the fiberglass mat 106 and the roof support below (not
shown) from the elements. A layer of pre-colored rock granules 110
may be disposed on top of the asphalt filled coating 108. As
discussed previously, a primary purpose of the layer of pre-colored
granules 110 is to protect the asphalt filled coating 108 from
outdoor weathering elements, such as UV light from the sun, that
may break down the asphalt filled coating 108 over time. The
pre-colored granules 110 also give the shingles 104 their color,
contributing to the house's esthetic appearance, although the
shingles 104 are limited in color to the combinations possible by
blending the pre-colored granules 110.
[0019] The asphalt shingles 104 may further comprise a second layer
of asphalt filled coating 112 disposed beneath the fiberglass mat
106, further contributing to the waterproofing properties of the
shingles 104. A back surfacing material 114 may be disposed beneath
the second layer of asphalt filled coating 112, and may be in
direct contact with the layer of plywood of the roof support 102,
as shown in FIG. 1A. As discussed previously, certain problems may
be associated with using pre-colored granules 110 during the
manufacturing process of asphalt shingles 104. Accordingly, a
system and method for manufacturing asphalt shingles without
requiring the use of pre-colored granules to make up the color of
the asphalt singles 104 is desired.
[0020] FIG. 2 is a cross-sectional drawing of a colored roof
covering 200, in accordance with the present disclosure. The
colored roof covering 200 may comprise a fiberglass mat 206, an
asphalt filled coating 208 disposed on top of the fiberglass mat
206, a second asphalt filled coating 212 disposed beneath the
fiberglass mat 206, and a layer of back surfacing material 214
disposed over the second asphalt filed coating 212.
[0021] The colored roof covering 200 may further comprise a layer
of top surfacing material 210 disposed on top of the asphalt filled
coating 208. The layer of top surfacing material 210 may replace
the pre-colored granule surface with similarly-sized minerals or
rocks, such as limestone, that may be painted in-line. The colored
roof covering 200 may use only one layer of top surfacing material
210 that may be comprised of individual granules. The granules may
be rock, clay, manufactured mineral, polymer plastic, or metal
flake material and may be applied to the asphalt filled coating
208. Because certain types of rocks are more readily available in
specific parts of the United States, roofing manufacturers may be
able to reduce manufacturing costs by using those rocks most
readily available in close proximity to each manufacturing
facility.
[0022] The exposed portion of the colored roof covering 200 is
typically referred to as the buttlap portion of the shingle and is
the portion of the shingle to which a layer of color coating 211
may be applied during the painting process. The layer of top
surfacing material 210 may be coated with the color coating 211
that provides a substantially uniform painted surface and allows
the colored roof covering 200 to be painted with a design, pattern,
or logo, which may not be possible with a shingle covered by
pre-colored granules. Whereas the pre-colored granules 110 in FIG.
1 have a conformal layer of color coating over each individual
granule, the color coating 211 may be a conformal layer over the
layer of top surfacing material 210 but not over the entire surface
of each individual particle that may make up the layer of top
surfacing material 210.
[0023] The color coating 211 may be either a paint that is painted
onto the layer of top surfacing material 210 or an ink that is
applied with an ink jet printer onto the layer of top surfacing
material 210. By using the color coating 211 instead of pre-colored
granules, unlimited shingle colors and/or patterns may be possible
by mixing two or more colors during the application process. The
color coating 211 may be designed to be out in the elements for the
lifetime of the colored roof covering 200, which could be up to 30
years or more depending on the particular shingle being
manufactured. The color coating 211 may also be designed to resist
fading when exposed to 30 years of sunlight, rain, and snow.
[0024] An industrial painting system such as those manufactured by
Nordsen or Cefla may be used to apply the color coating 211 with a
computer controlled painting system. The painting system may be set
up to be pre-programmed with the desired colors and/or color
patterns. In an exemplary embodiment of a painted color coating
211, suggested paints may include acrylic-based paints, oil-based
paints, polyurethane acrylate-based paints, polyvinylidene
fluoride-based paints (PDVFs), or any combination thereof. In some
embodiments, weathering properties from the colored roof covering
200 using the color coating 211 may be optimized wherein at least
70% of the material is the PVDF. With the current formulation of
paints available, the paint or ink coating 211 may be applied as
thin as 5 microns thick. There are numerous potential suppliers of
these types of paints, including companies such as Sherwin Williams
and Arkema.
[0025] Alternatively, an industrial ink-jet system such as those
supplied by Electronics for Imaging, Inc. (EFI) may be used to
apply an ink color coating 211 with a computer controlled system.
The industrial ink-jet system may work similarly to the ink-jet
desktop printers used in many homes and offices. In an exemplary
embodiment of ink color coating 211, the components of the color
coating 211 may include a combination of oligomers, monomers, a
photo initiator, colorants, and modifiers and additives. There are
numerous potential supplies of these types of ink, including
companies such as Sartomer.
[0026] An optional layer of pre-coating covering (not shown) may be
applied on top of the layer of top surfacing material 210 before
the layer of color coating 211 is applied. The layer of pre-coating
may be used to achieve a more consistent shingle color between
manufacturing plants and/or production lines if the same layer of
top surfacing material 210 is not used consistently between
manufacturing plants and/or production lines. The layer of
pre-coating may be a neutral color, which may allow a manufacturer
to change the layer of top surfacing material 210 during production
without having to be concerned about the finished color of colored
roof covering 200 differing slightly from another run of painted
shingles.
[0027] Additionally, a layer of clear coating (not shown) may also
be optionally applied on top of the layer of color coating 211. The
layer of clear coating may be used to achieve the desired shingle
appearance and/or may be used to provide the desired life
expectancy of the shingle, which could be 30 years or more with
today's shingles.
[0028] By utilizing the color coating 211, the roofing manufacturer
may no longer have to have separate storage silos for each color of
pre-colored granules and would potentially only need one or two
storage silos for all of the granules or other materials that make
up the layer of top surfacing material 210, depending on the rate
of production and how quickly the stock of the layer of top
surfacing material 210 can be refilled by suppliers. Furthermore,
with a color coating 211, the layer of top surfacing material 210
may not need to be made from a specific material and may be
purchased locally based on the availability and price of what may
be available closest to each manufacturing facility. Even if two
different manufacturing facilities use different layers of top
surfacing materials 210, perfect color matching between
manufacturing facilities may be achieved by using the same color
coating 211 because manufacturing facilities would no longer have
to be concerned with using the exact same ration of colors of
pre-colored granules when trying to match colors between
manufacturing facilities and/or production lines.
[0029] The color coating 211 on top of the layer of top surfacing
material 210 may further help to control manufacturing and
inventory costs because scrap from color changes normally
associated with pre-colored granules may be significantly reduced
and there may be reduced inventory control complexity required
because the raw layer of top surfacing material 210 would not have
to be stored in separate silos based on their original colors.
Further, the total mass of the colored roof covering 200 may be
reduced because the need for the pre-colored granules may be
eliminated and may not actually be as important to the appearance
of the colored roof covering 200 as it is with a traditional
asphalt shingle with pre-colored granules. Smaller sized and/or
lighter weight granules, such as Grade 18 granules, may be used for
the layer of top surfacing material 210, and less asphalt filled
coating 206 may be necessary to bond the smaller particles of the
layer of top surfacing material 210 to the fiberglass mat 206.
[0030] Even further, the color coating 211 on top of the layer of
top surfacing material 210 may synergistically help to extend the
life of the colored roof covering 200. The top surfacing material
210 protects the layers beneath from outdoor weathering elements
such as sunlight, rain, snow, and hail. The color coating 211 may
form a film barrier over the top surfacing material 210 and provide
additional protection against erosion by air, moisture, and/or UV
light. In comparison, the shingle 104 shown in FIG. 1B has only the
pre-colored granules 110 to protect the filled coating 108 from
weathering elements. By incorporating the color coating 211 into
the colored roof covering 200 of FIG. 2, additional time is
required for the weathering element to penetrate the additional
barrier provided by the color coating 211, thereby extending the
life of the colored roof covering 200.
[0031] FIG. 3 is a flow diagram of a process 300 for manufacturing
the colored roofing covering of FIG. 2, in accordance with the
present disclosure. In an embodiment, asphalt shingles are made on
a web of non-woven fiberglass material comprising a fiberglass mat
302, wherein the web can range from approximately 36''wide to 68''
wide, although larger and smaller webs may also be used. In
operation, the process 300 begins with the fiberglass mat 302 as
the skeleton upon which the rest of the layers of a colored roofing
covering are added. At action 304, asphalt 306 and rock filler 308
may be mixed together in a mixer 310, creating the asphalt filled
coating 306, 308, and then the asphalt filled coating 306, 308 may
be applied to the top and the bottom surfaces of the fiberglass mat
302, respectively as the fiberglass mat 302 is fed through a
roller. At action 312, a layer of top surfacing material 311 may be
dropped onto a top surface of the asphalt filled coating 306, 308
that was applied on top of the fiberglass mat 302. At action 316, a
layer of back surfacing material 314 may be dropped onto a bottom
surface of the asphalt filled coating 312 that was applied to the
bottom of the fiberglass mat 302.
[0032] At optional action 318, a neutral pre-coat 319 may be
applied on top of the layer of top surfacing material 310. The
neutral pre-coat 319 may be necessary to achieve consistent shingle
colors between manufacturing facilities. At action 320, a color
coating 322 may be applied to the layer of top surfacing material
310 and/or neutral pre-coat 319 layer to form a color way. If the
color coating 322 is an ink, the color coating 322 may be applied
with an industrial-sized ink jet printer. If the color coating 322
is a paint, the color coating 322 may be applied by an automated
spray painter. The color coating 322 may be stored in storage tanks
(not shown) based on the color or the paint or ink. The color
coating 322 may be applied as a single color, as a uniform mixture
of two or more colors, as a speckled color, or as a pattern or
design. At optional action 324, a clear coating 326 may be applied
on top of the layer of paint or ink coating 322. The clear coating
326 may be necessary to achieve the desired shingle appearance
and/or to improve the expected lifetime of the shingle by further
protecting the colored roofing covering from UV light.
[0033] At action 328, the colored roofing covering may be cured by
heat, UV light, or electron beam in order to cure the various
layers of the colored roofing covering together and to prevent the
color coating 322 from running. At action 330, as the colored
roofing covering is being cooled after curing, the colored roofing
covering may be cut and/or laminated, as is typical in the shingle
industry. The sheet of colored roofing covering may be cut into
lanes that are either cut into individual shingles or into lanes
that may be laminated together into multi-layer strips, which may
be later cut into individual shingles. At action 332, the colored
roofing covering may be packaged and palletized. At this point, the
packaged colored roof coverings may be ready to be shipped from the
manufacturing facility to a wholesaler, a retailer, a roofing
contractor, or directly to an end consumer.
[0034] While various embodiments in accordance with the disclosed
principles have been described above, it should be understood that
they have been presented by way of example only, and are not
limiting. Thus, the breadth and scope of the invention(s) should
not be limited by any of the above-described exemplary embodiments,
but should be defined only in accordance with the claims and their
equivalents issuing from this disclosure. Furthermore, the above
advantages and features are provided in described embodiments, but
shall not limit the application of such issued claims to processes
and structures accomplishing any or all of the above
advantages.
[0035] Additionally, the section headings herein are provided for
consistency with the suggestions under 37 C.F.R. 1.77 or otherwise
to provide organizational cues. These headings shall not limit or
characterize the invention(s) set out in any claims that may issue
from this disclosure. Specifically, a description of a technology
in the "Background" is not to be construed as an admission that
technology is prior art to any invention(s) in this disclosure.
Furthermore, any reference in this disclosure to "invention" in the
singular should not be used to argue that there is only a single
point of novelty in this disclosure. Multiple inventions may be set
forth according to the limitations of the multiple claims issuing
from this disclosure, and such claims accordingly define the
invention(s), and their equivalents, that are protected thereby. In
all instances, the scope of such claims shall be considered on
their own merits in light of this disclosure, but should not be
constrained by the headings herein.
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